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Hot!Another Escort Van Project: 77 Mk2

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Re: Another Escort Van Project: 77 Mk2 2021/01/18 19:01:38 (permalink)
+1 (1)
Deano 
Depends on what size diff and tyres you intend to run . 
You can cut out the back inner wheel arches completely and put tubs in or what i do is put in infill panels leaving the existing inner arches in place just cutting off around the join . 
You can buy the infill panels pre shaped : 
 https://www.gartrac.com/collections/escort-mk1-works-fabrication-parts/products/escort-mk1-rear-steel-inner-arch-extension-pair
But its not that difficult to make a cardboard template to do them yourself. 
I make them and butt them upto the bubble the tack them on the top and the bottom to the bubble every 10mm 
Just make sure when you fit the bubbles there identical on both sides as its prominent once painted that one is 10mm higher on one side than the other when looking from the rear . 
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deano
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Re: Another Escort Van Project: 77 Mk2 2021/01/19 09:13:25 (permalink)
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thanks Bonus, that's exactly what I needed to know.
My goal is to pretty much replicate the white van at the start of this thread, down to the wheels which I think are 15" Compomotive ML's.
I'd planned to fit the arches, then measure from there back to the current hubs to see what size is possible.
I'm not certain what the diff is that's in it at the moment, haven't got that far.
I don't think it is anything special, the previous owner suggested  it might be a 2L Mk2 diff, as it has mounts for a sway bar. Looking at it though I thought it was less beefy than what is in my 4 door.
Will suss that out further.
 
I'll cut the wheel tub as suggested at the join, and pattern up an infill.
 
I recieved my panel delivery came yesterday, sills,floorpan and heater bubble. I expected they would need some tweking to fit, but did not expect they would be so rough. The floor pan had ripples in it where the stamping should have been flat, it looked like I made it. The heater bubble had been manually panel beated to get some dents out, and still needs work. And they were not painted like you see online, just left bare metal. 
Overall, if thats the quality of M*gnum Panels, im not too excited.
 
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Re: Another Escort Van Project: 77 Mk2 2021/01/19 20:46:58 (permalink)
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Deano 
did the panels have magnum labels on them ? 
Ive never had an issue with magnum , there floor panels and in fact all there panels fit really good and present as a genuine panel . 
I have magnum sills , heater bubbles and floors in my shed and are all identical , painted matt black and have not been re-worked 
Ive bought a few cheaper variants in the past that are poor and look like they have been stamped by a child so maybe you have ended up with these ...i know some are now getting made in the land that doesn't like Australian imports and are being sold as Magnum ..
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Re: Another Escort Van Project: 77 Mk2 2021/01/27 13:32:00 (permalink)
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I dont know what happened to the last post anyhow, I'll retype.
yes they have Magnum stickers, but I have a Zebra thermal printer at work, and could bang those out in a few minutes.
Anyhow, see what you think. To me, just a bit dissapointing thats all.
 
 

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deano
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Re: Another Escort Van Project: 77 Mk2 2021/01/27 13:42:46 (permalink)
+1 (1)
this weeks progress was alittle slow.
 I squewered my ankle on a 6" nail and tore it open a bit. Well abit more than a bit.
It probably needed stitches. Question if you injure yourself and need stitches but the wife doesnt know, do you really need stitches?...
 
Anyhow, I persisted with the welding (without gas) despite all of the good suggestions to the contrary, and ended up happy with the result.
2 skims of filler, and she's ready for some etch primer now. 
Got the passenger door off to investigate the sill further, and also removed the front guard, so a couple of Escort apprenticeships done I feel there.The hinge pins were a bit of fun, bottom one knocks up, and topn one knocks down. A Milwalkee drill driver extension bar is the perfect size substitute for a pin tool.
 
The inner bulkhead does not look too exciting in places. 
Would this be ok to repair with 1mm (the capacity of my folder) or should it be thicker than std panel steel?
 
 

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blue74
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Re: Another Escort Van Project: 77 Mk2 2021/01/29 13:32:10 (permalink)
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Ouch, your ankle must be sore!
 
The van is coming along nicely, at least the floor panels you purchased will be hidden under the carpet.
 
The steel I use is just under 1mm, about .9, you may be able to get 1.2 and push your folders limits, it will be a bit easier to weld but harder to form. I only use a mig with gas for welding body panels, it's worth the money and you won't look back once you have tried it.
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martymexico
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Re: Another Escort Van Project: 77 Mk2 2021/01/30 10:56:20 (permalink)
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Have you had your tetanus shot recently just so you don't catch rusty diseases. Last year I was installing a lokka diff into my d22 front diff in a bench and it decided to walk and fall off the side catching my shin on the way down. Not much pain but blood, skin and grease don't mix, I hosed the tear out as best I could and Dettol'd it before closing the flap and taping it up as I didn't have super glue handy. The 50c coin slot scar still hurts when bumped. A nurse friend said it should've had stitches but tape did the job as good😁.
With the floor panels you've got there the front folded bit that gets cut off and binned as it would cover the ribbing where the seats bolt to. I usually remove the rib as part of the repair process and it also hides the weld join, plus the rib could also be rusted out so it'll be handy to make new ones while there.
How bad are the jacking points inside the sills? it's a brilliant rust area for vans
#22
deano
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Re: Another Escort Van Project: 77 Mk2 2021/01/31 09:19:41 (permalink)
+1 (1)
yes, I was lucky with the tetnus. We had a new addition to the family (not immediate family, although I would tomorrow, but the boss is getting a bit too old now ()), and before we could see the new bubs, we had to get an imunisation jab. Part of that, was Tentnus as well, so that was a bonus (sorry Bonus), done in 2018.
Hosing the tear out sounded fun Marty.
I havent looked at the jacking points yet, I'm trying to focus on one section (ok, 3 sections) at a time, or else i'm sure that i'll sit down at one stage and the reality will hit, as it will look like a total basketcase.
 
Currently:
-1 rear door stripped and sanded
-passenger door off
-passenger guard off and 1/2 stripped
-passenger inner sill and floor cut out (previous owner)
-driver floor and seat crossmember cut out (previous owner). I see what you mean Marty about floor pan tab.
-anywhere thats painted black on the bulkhead  is likely to be paint over no more gaps
Update: that window pictured above is now primed, and came up ok to me. It needs some high build and spot putty just to sharpen up the fold lines a little, but thats ok for now.
 
I welded up the antenna hole in the guard, just to do something, and have started to make corner panel infills for the front of the well. Problem is, the corners on both sides were already chopped out, so it's  guesswork as to how it should look. In my last trip to metalland I bought just some sheet offcuts, and bingo, there as some 1.2? Definitely harder to form, but the folder did ok actually. The best thing I learnt, the folder makes a great clamp just to hold steel why you cut it. Worth buying for that alone. My other find was the poly strip disks for the grinder, gee they do a great job. Sorry no pics, i'm meant to be doing something else, and will be off air for a week.
 
I got the bubble arches last night (they are Magnums ,and yes painted black as norm), just have to figure out which is which 
Mind you, none fit with the wheels on, the inner stamping flange needs trimming first.
The temptation is so great just to start hacking the rear 1/4 to get fitting, but the van needs more strengthening before I start cutting more bit out, so I have to wait....
 
I'm thinking I really might have to make a roll over jig though. I practically have 1/2 already with dads bus engine stand. welding the sills and inner arches would be much easier.
I emailed Compomotive Uk to see if they could identify roughly what the rear wheels were on the white bubble van. Mainly the offset or backspace. I know it probably impossable to tell from a pic, but I like the way the spokes look longer because of the disk. Wheel ocd. And I think the wheel color will be gold.
Just cant pic the van and stripe color. 
Time to move past orange.
Have a good week fellas. Keep your fingers and toes.
 
 
 
 
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Re: Another Escort Van Project: 77 Mk2 2021/01/31 10:24:20 (permalink)
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Great lot of updates here!

Looks like its coming together very well and your learning alot which is always the fun part of the project!

Keep the photos coming!

Maybe one day ill get myself a van
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Drewdog
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Re: Another Escort Van Project: 77 Mk2 2021/02/07 12:23:12 (permalink)
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Just finding out what I missed after a month off the social media.
Congrats Deano on the Van, birthday and progress so far. Watching with interest...

GT Cortina Project "The Ugly Duckling"
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Re: Another Escort Van Project: 77 Mk2 2021/02/07 20:51:47 (permalink)
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hey Drew, I thought you'd been quiet recently, almost MIA.
Nothing wrong with a social Media detox.
 
Last week I caved into the pressure after 50 years and joined facebook for the first time.
Theres an escort FB group that has some parts come up at semi-reasonable prices, so I had to join so I can get in the fun, plus I'm going to need some bits for the van. Pinto/zetec/diff/struts/brakes/seats anyone?
(Still not on Linkedin,Instagram but we do have whatsapp to catch up on the kids)
 
Anyhow, some progress on the van today, will post pics tomorrow.
It seems theres bugger all stock coming in from the UK atm, so I made an inner sill from scratch instead. 
I think I just about worked all day for about $100 bucks.
 
(The vans starting to look good though, at least one one side).
 
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Re: Another Escort Van Project: 77 Mk2 2021/02/08 13:05:46 (permalink)
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some pics from weekend 4.
Inner and outer sills cut off.
Do the coupes have the stiffening box section also, or just vans?
Obligatory pic of the cut offs, and a huge file of good aussie dirt.
The folder got a good work out.

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Re: Another Escort Van Project: 77 Mk2 2021/02/08 13:13:08 (permalink)
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might just tape the bubbles on, although the rat rod wheels are growing on me.
If I can find the Gold Compomotive wheels in Australia that would be good.
 
Next job is to hang the door again, then start to stopweld the sills in place.
 

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Re: Another Escort Van Project: 77 Mk2 2021/02/08 20:48:18 (permalink)
+1 (1)
Are you sure they are compomotive and not performance but in a large spec? Im leaning towards 8-10inches wide

Im sure one of the fb pages would have the answer - the owner might even be able to be tracked down and give you the real details of them
 
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Re: Another Escort Van Project: 77 Mk2 2021/02/08 22:42:21 (permalink)
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I think you've got the back arch on backwards, it belongs on the other side
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